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Abstract

This thesis looks at the capabilities of cutting thin webs on Wire EDM machines that are difficult or impossible to machine using conventional methods. Covered is an investigation of how different material and web thickness affect the capability of machining thin-walled parts.

• Machine settings and offsets were limited to the default setting selected from the Sodick AQ325L database.

• Two different pre-test cuts were taken on the material to check for web bending during the cutting process.

• Hardness was tested for comparison of the web heights.

This thesis shows that bending increased as webs became thinner and that bending occurred toward the wire as the second side of the web was cut. Bending does affect the height of the web. Physical properties of materials also impacted the height of the web with the hardest material staying intact during the cutting process. This study shows that two factors, physical properties of materials and web thickness, significantly affect cutting results for thin web parts.